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SEPTEMBER/OCTOBER 2010 • VOL 11, NO. 5 • www.LMTinfo.com

Contents

ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS

FEATURES 8

© NIKART-FOTOLIA.COM; © KTSDESIGN-FOTOLIA.COM © VIC SPANNER-FOTOLIA.COM

EQUIPMENT HEALTHCARE Keeping Motors And Gearboxes In Tip-Top Shape

Want to insure against the failure of these critical systems? Protect them with the correct lube prescriptions and protocols.

Ken Bannister, Contributing Editor

PROCESS IMPROVEMENTS 14

3 More Reasons For Premature Bearing Failure (And How To Avoid Them)

Listening to what your failed bearings are telling you today can help you minimize problems tomorrow.

Special To LMT From NSK

UTILITIES MANAGER 18

Big Money Talks: Today’s Entitlement/Tomorrow’s Privilege Energy conservation will only go so far. Is there a Plan B for bridging what could be yawning gap between our electricity supply and demand?

William C. Livoti

19

Protecting & Optimizing Your Air Compressors Count on synthetic lubricants to help you do it all.

Jane Alexander, Editor, with Michael J. Hawkins, ExxonMobil Lubricants & Specialties

DEPARTMENTS 5 6 22 24 25 30

From Our Perspective Motor Decisions Matter The Green Edge Solution Spotlight Problem Solvers Supplier Index

GI Bill Will Pay For CMRP Certification Exams The Society for Maintenance and Reliability Professionals Certifying Organization (SMRPCO) has announced that the Certified Maintenance and Reliability Professional (CMRP) certification program has been approved by the Department of Veterans Affairs, and will be added to the list of certification exams for which military personnel and veterans are eligible to receive reimbursement. For more information, visit www.smrp.org

SEPTEMBER/OCTOBER 2010

www.LMTinfo.com | 3

Changed the way you run. ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS

September/October 2010 • Volume 11, No. 5 ARTHUR L. RICE President/CEO arice@atpnetwork.com

BILL KIESEL Executive Vice President/Publisher bkiesel@atpnetwork.com

JANE ALEXANDER Editor-In-Chief jalexander@atpnetwork.com

Changes the way your plant runs.

RICK CARTER Executive Editor rcarter@atpnetwork.com

KENNETH E. BANNISTER RAY THIBAULT, CLS, OMA I & II RAYMOND L. ATKINS Contributing Editors

RANDY BUTTSTADT

Director of Creative Services rbuttstadt@atpnetwork.com

GREG PIETRAS

Editorial/Production Assistant gpietras@atpnetwork.com

ELLEN SANDKAM

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LUBRICATION MANAGEMENT & TECHNOLOGY

Direct Mail esandkam@atplists.com

EDWARD KANE

Reprint Manager 800-382-0808, ext. 131 ekane@fostereprints.com

Editorial Office 1300 South Grove Ave., Suite 105 Barrington, IL 60010 847-382-8100 / FAX 847-304-8603 www.LMTinfo.com

Subscriptions FOR INQUIRIES OR CHANGES CONTACT JEFFREY HEINE, 630-739-0900 EXT. 204 / FAX 630-739-7967 Lubrication Management & Technology (ISSN 19414447) is published bi-monthly by Applied Technology Publications, Inc., 1300 S. Grove Avenue, Suite 105, Barrington, IL 60010. Periodical postage paid at Barrington, IL and additional offices. Arthur L. Rice, III, President/CEO. Circulation records are maintained at Lubrication Management & Technology, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Lubrication Management & Technology copyright 2010. No part of this publication may be reproduced or transmitted without written permission from the publisher. Annual subscription rates for nonqualified people: North America, $140; all others, $280 (air). No subscription agency is authorized by us to solicit or take orders for subscriptions. Postmaster: Please send address changes to Lubrication Management & Technology, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Please indicate position, title, company name, company address. For other circulation information call (630) 739-0900. Canadian Publications Agreement No. 40886011. Canada Post returns: IMEX, Station A, P.O. Box 54, Windsor, ON N9A 6J5, or email: cpcreturns@wdsmail. com. Submissions Policy: Lubrication Management & Technology gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc., permission, by an irrevocable license, to edit, reproduce, distribute, publish and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned. Printed in U.S.A.

SEPTEMBER/OCTOBER 2010

FROM OUR PERSPECTIVE

Ken Bannister, Contributing Editor

An Emperor Without Clothes?

R

emember the story of “The Emperor’s New Clothes?” Once upon a time, a vain Emperor engaged the services of two swindlers masquerading as weavers, who promised to make him a suit from magic cloth. Amazingly, the new clothes would be visible only to persons competent and fit for their jobs. Thus, when sent to check on the progress of the project, the Emperor’s representatives reported that the non-existent suit was magnificent! Had they admitted there were no clothes, they would have been labeled incompetent or unfit! Checking for himself, the Emperor also proclaimed the new clothes to be magnificent, lest he, too, be deemed incompetent or unfit for his position. Only when he ostensibly donned his magic finery and paraded in public did a child— with no position to protect—clarify what was painfully obvious: that the Emperor was naked. Still, the Emperor continued to proudly march on. This fairy tale is a metaphor, of course. For our purposes, it can be used to describe a management that chooses to believe it has an effective program in place, and those working in the program who see the reality (or pretense), but choose not to be contrary for fear of reprisal. Visiting a self-proclaimed “World-Class” facility recently, I was surprised to hear managers claim they had simultaneously implemented their maintenance program based on Lean Maintenance, Overall Equipment Effectiveness (OEE), Reliability Centered Maintenance (RCM), Total Productive Maintenance (TPM) and Preventive/Predictive Maintenance (PM/PdM). This “combined approach,” they avowed, had led to huge gains in equipment uptime and reliability—despite an asset management system that wasn’t set up to report Mean Time Between Failure or Availability. Apparently, management felt its level of investment in the system had to be producing the desired effect! Unfortunately, in examining the plant’s lubrication-management program, I found the typical PM job task “Lubricate as necessary” still in use,

SEPTEMBER/OCTOBER 2010

with the program’s success relying on a recently created “oiler” position. The new “oiler” had been chosen primarily because of seniority. Lacking any experience with lubricants or their application, he believed that the purchase of new grease guns constituted a lubrication-management program!

If your program is in disarray and your ‘Emperor’ has no clothes, let this magazine be your voice. Many of the maintainers with whom I spoke off the record considered the new maintenance approach to be “smoke and mirrors”— and confusing and detrimental to asset health. They further believed there was no real program in place, but felt unable in these economic times to criticize the situation, albeit constructively, in front of management. Not surprisingly, maintainers had not been part of the programimplementation team. Having visited hundreds of facilities in similar denial over the years, I’ve continued to be stunned (and saddened) by the type of short-sighted approach that views the creation of an “oiler” position and purchase of new grease guns as state-of-the-art lubrication management. If your lubrication efforts are in this type of disarray, and your Emperor has no clothes, let this magazine be your voice. Leverage the tips, strategies and solutions you find in our pages to show management the real meaning of a “Best-Practice Lubrication Program.” Good luck! And what about the “World-Class” operations referred to earlier? As a consultant, I was the “child” who pointed out the absence of “clothes.” Alas, to date at this plant, the Emperor has chosen to proudly (and nakedly) march on. LMT kbannister@engtechindustries.com

www.LMTinfo.com | 5

BOOSTING YOUR BOTTOM LINE

Make Energy An Asset, Not An Afterthought

I

n an April 2010 survey of leading businesses entitled “From Shop Floor to Top Floor: Best Business Practices in Energy Efficiency,” the PEW Center on Global Climate Change describes a shift in how companies such as Dow, IBM and Toyota approach energy. The authors’ conclusions? Setting ambitious long-term energy-saving goals saves money, avoids greenhouse-gas emissions and improves employee morale. Ultimately, survey participants have boosted their bottom lines by approaching energy as a core asset to be managed, rather than as an expensive afterthought. Traditionally, however, efficiency opportunities have been addressed through incremental improvements. While such savings are notable, managing efficiency on an organization-wide basis greatly expands the potential. In this new paradigm where energy is viewed as an “asset,” more comprehensive changes are pursued. This paradigm shift can be viewed in the context of how your facility approaches energyintensive equipment, such as motors. Imagine the effects on your bottom line from upgrading to premium-efficiency motors one by one, versus an approach based on a comprehensive motormanagement plan. For example, a proactive motor-management plan would involve maintaining an inventory of all motors and ensuring that energy was included in the analysis of when and how they are to be repaired or replaced. Incorporating the motor-management plan as a business strategy assures that all personnel contribute and adhere to it. What’s the impact to your bottom line? It’s likely to be a very large number: Multiply the savings you would achieve by upgrading one motor by the number of motors in your facility—the U.S. Department of Energy has estimated this could be $900/year for a 75 hp motor—and add to that the avoided productivity losses associated with being unprepared when critical motors fail.

6|

LUBRICATION MANAGEMENT & TECHNOLOGY

Another important finding of the PEW study was that at leading companies, senior management supports managing energy as an asset. This approach permeates all levels of the companies’ organizational charts. As a result, the benefits extend beyond the bottom line to include improved productivity by stimulating technical and process innovations, such as reductions in water use, materials waste, labor costs and production downtime. Where to start? If the successes achieved by companies in the PEW Center survey seem to be beyond your company’s budget, resources or manpower, you may want to try something simple that can still have plenty of impact: Start managing your energy asset by managing your motors. If your facility is like most others, motordriven systems consume a large portion of your energy use. The sponsors of the Motor Decisions MatterSM Campaign have developed a suite of resources to help you and your team be more effective in managing those systems and, in turn, your energy asset. Visit the MDM Website (www.motorsmatter.org) to access these resources and begin making energy an asset, not an afterthought. LMT For more info, enter 01 at www.LMTfreeinfo.com

The Motor Decisions Matter (MDM) campaign is managed by the Consortium for Energy Efficiency (CEE), a North American nonprofit organization that promotes energysaving products, equipment and technologies. For further information, contact MDM staff at mdminfo@cee1.org or (617) 589-3949.

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EQUIPMENT HEALTHCARE

Keeping Motors And Gearboxes In Tip-Top Shape Want to insure against the failure of these critical systems? Protect them with the correct lube prescriptions and protocols. Ken Bannister Contributing Editor

D

oes your computerized maintenance management system (CMMS) currently classify your driver/driven motor gearbox combination units as two separate assets—motor and gearbox? Or does it view them as a single combined asset, or as a sub-component of a piece of proprietary equipment? Does your lubrication PM work instruction for both motor and gearbox spell out the lubricant type and amount required, or is the statement to “Lubricate as Necessary” the only guidance you have? In either scenario, if you’re not treating your motors and gearboxes as separate entities, each requiring its own detailed lubrication regimen, you have already ventured down the slippery slope to premature failure.

8 | LUBRICATION MANAGEMENT & TECHNOLOGY

SEPTEMBER/OCTOBER 2010

EQUIPMENT HEALTHCARE

Assuring motor and gearbox reliability calls for a two-pronged plan of attack: 1. Good alignment practice and, more importantly, 2. Effective lubrication practice. The driver/driven combination of a motor/gearbox is an assembly of two specific entities—one electro-mechanical (an always-serialized motor); the other purely mechanical (an often-serialized gearbox)—that must be treated individually when assessing their lubrication needs. When treated with care and respect, these entities can be expected to outlive their driven components. This short overview focuses on the major symptoms of poor lubrication practices and some straightforward maintenance strategies for making your lubrication program more effective in protecting the health and well-being of your hardworking motors and gearboxes. Motor lubrication In simple terms, motors are electro-mechanical devices that turn electrical energy into mechanical energy. The motor magnets and windings are wound on to a shaft simply supported by two or more bearings at either end of the motor frame. These bearings—usually rolling-element types such as ball, roller or needle bearings—are the only lubrication points on

a motor. They are almost always grease-lubricated. Most fractional- and small-horsepower motors make no provision for bearing lubrication (no grease nipples provided). A unit like this is typically designed to utilize the original grease lubricant filled within its sealed bearing cavity to provide lubrication throughout its service life. With smaller motors, loads are usually light; the lubricant rarely needs replenishment if a unit is balanced and aligned correctly. Depending on the motor design and manufacturer, external grease fittings usually start to appear on motors rated 20 hp and above—and always are evident on motors 50 hp and above. When motors become more powerful and heavier, more static and driven load is placed on the bearing points, thus requiring grease replenishment on a more frequent basis. If a motor is to operate at peak efficiency, its bearing cavities (the available space between the balls, raceways, cage and seals) should only be filled to 30-50% of capacity with lubricant. Without the air space this affords, the grease would not be able to penetrate and work within the bearing contact surfaces. Instead, a condition known as “churning” (in which the fluid friction of the grease tries to retard the easy moving action of the bearing) would be set up. In order to overcome this internal resistance, a motor must draw more power and the resulting frictional heat breaks down the lubricant properties, significantly reducing its working life. Motors “designed” to be greased will have a grease nipple located on top of the motor at each end. Located 180 degrees from the nipples is a capped drain plug that’s designed to be unscrewed and allow excessive grease to channel through

SICK SITUATION: If your grease-gun tip looks like this, DON’T use it on a motor bearing (or any other bearing, for that matter). Always clean grease-gun tips with lint-free rags. (Photo courtesy of EngTech Industries, Inc.)

SEPTEMBER/OCTOBER 2010

www.LMTinfo.com | 9

EQUIPMENT HEALTHCARE

Diligence must also be exercised in performing the lubricating procedure to ensure no dirt is introduced inadvertently into the bearing cavity due to an unclean grease gun tip or grease nipple. To ensure that motors don’t run hotter than they are designed to run, and windings are never used as grease reservoirs, heed the following tips: Motor lubrication tips… n Ensure all maintainers are fully trained in how to correctly lubricate a motor. n Remove grease nipples from all fractional- and lowerhorsepower motors (20 hp and less) and run to fail. n Identify the correct grease to use on the PM work order and with a tag affixed to each motor. n Identify the correct grease requirement on the PM work order by number of shots, after ensuring all grease guns in the plant have identical output per shot.

SICK SITUATION: This photo of a medium-sized motor shows a dirty grease nipple, traces of two different greases (a gold-colored grease and a red one) and a broken guard. (Photo courtesy of EngTech Industries, Inc.)

the bearing and out of the motor during lubrication. If this drain is kept capped during the greasing process, excessive lubricant will channel directly through the bearings past the seals and into the motor windings—where it will eventually “cook” as the motor spins. Unfortunately, motors with grease points suffer a disproportionate amount of premature failures caused by over-lubrication, mixing of lubricants and contaminant inclusion. Over-lubrication, by far the biggest sin, results from the mistaken belief that if a little lubrication is good, “a lot of lubrication is a lot better!” Motors are designed with a specific grease lubricant in mind—usually one with dielectric properties so as not to ground out the motor if the grease mistakenly enters the windings. Maintenance teams must exercise great diligence in ensuring the correct grease is always used and not mixed with another type, since not all greases are compatible. Mixing incompatible lubricants is a sure way to greatly reduce a bearing’s (and a motor’s) life.

n Investigate the use of automated single-point lubricators for roof fans and remote locations. Gearbox lubrication Gearboxes are, essentially, simple, self-contained mechanical devices that allow power to be transmitted from an input shaft to an output shaft at different speeds through the meshing of different-sized gear sets held on each shaft. The gears and shafts are supported on bearings contained within a sealed “box” that also serves as a reservoir for the lubricating oil. Gearbox dimensions can range from palm-size to room size and, with few exceptions, are oil-lubricated. Depending on the style and size, gearboxes employ a number of methods to move the lubricant over the gears and bearings, the most popular being: n Splash lubrication…This is the most common gearbox lubrication method. It involves filling the reservoir partway with lubricating oil to ensure partial coverage of all the lower mating gears. At speed, these gears use surface tension on their teeth to “pick up” lubricant and transfer to other gears and bearings through meshing and by “flinging and splashing” the lubricant in all directions within the sealed reservoir. Continued on page 12

If you’re not treating your motors and gearboxes as separate entities, you’ve already ventured down the slippery slope to premature failure.

10 | LUBRICATION MANAGEMENT & TECHNOLOGY

SEPTEMBER/OCTOBER 2010

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EQUIPMENT HEALTHCARE

n Pressure or force-fed lubrication…This lubrication method is typically found on mid- to large-size gearbox assemblies. It employs a gear-driven pump, usually located inside the gearbox, to work in conjunction with the “splash” method. The pump picks up lubricant through a pick-up filter screen and pumps it at pressure through an internal piped delivery system to bearings and gears that would be difficult to service with traditional “splash” lubrication. A replaceable or washable filter and pressurerelief valve are employed within the system to further protect the gearbox wear surfaces from harmful particles.

n Hot gearbox…This situation frequently results from excessive dirt on the outside of a gearbox, which then creates a thermal blanket that wants to “cook” the oil inside. Incorrect lubricant viscosity, caused by the mixing of lubricants or wrong lubricant choice, will cause excessive heat through fluid friction (too thick), or boundary metal-to-metal contact friction (too thin), both of which cause the oil to overheat and prematurely fail. Too little lubricant in the reservoir results in boundary-layer friction. Conversely, overfilling of the reservoir will create a churning and foaming of the lubricant

n Mist or atomized lubrication…This method of lubrication is usually reserved for the largest of gearboxes. It involves a vane pump that picks up lubricant from the reservoir and “flings” it at a plate, causing it to atomize into a fog. This fog then saturates all the mechanical components within the sealed gearbox.

Both conditions will significantly reduce the life of the lubricant and, correspondingly, the service life of the gearbox. They both require more power to be drawn from a motor—which wastes precious energy. To get the longest and most productive service life from your gearboxes, keep the following lubrication tips in mind:

In all cases, the lubricant provides surface-wear protection, corrosion protection of metal surfaces and cooling of gearbox internals. No wonder that the correct choice of lubricant is essential to its longevity. Typically, gearbox lubrication problems manifest themselves in two main ways:

Gearbox lubrication tips… n Ensure all maintainers are fully trained in how to correctly perform gearbox lubrication.

n Reservoir sludge…This malady often shows up after the mixing of incompatible lubricants, during oil changes or top-up procedures. It can cause additive packages to deplete faster than designed, resulting in a drastic viscosity change. Water introduced through a cleaning process or condensation within gearboxes subjected to varying heat cycles can mix with the detergents and soaps in the lubricant, creating a thick soap sludge. Oxidation of a lubricant that has been subjected to extended use, overheating or contamination can cause the lubricant to thicken into a damaging sludge that is difficult to pump around the gearbox.

When treated with care and respect, motors and gearboxes can be expected to outlive their driven components. SICK SITUATION: Although this overfilled gearbox does have a maximum-level lubricant indicator, it does not have a minimumlevel indicator. (Photo courtesy of EngTech Industries, Inc.)

12 | LUBRICATION MANAGEMENT & TECHNOLOGY

SEPTEMBER/OCTOBER 2010

EQUIPMENT HEALTHCARE

Shaft Alignment

& Geometric Measurement

HEALTHY SITUATION: This small-hp motor/gearbox combination unit has a sight gauge (to right) that clearly indicates high/low gearbox oil levels. (Photo courtesy EngTech Industries, Inc.)

n Attach a label to the reservoir, clearly indicating the correct lubricant manufacturer, product name and viscosity to be used. Clearly indicate the same information on the PM work order—without exception! n If the reservoir is regularly cleaned with water, ensure the fill cap and breathers (if applicable) are waterproof and in place at all times, or position a water deflection shield over the reservoir.

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n Always ensure the correct lubricant is being used for the application’s ambient temperatures. When changing lubricants, make sure the cap and breathers are always reinstalled, and that the lubricant is transferred using dedicated clean equipment. n Use oil analysis to determine when the oil is starting to “break down” its additive package and in need of change. n Make gearbox cleanliness an essential part of your PM program. n Consult the gearbox specification manual, or with a lubricant expert, to ensure your lubricant viscosity choice is correct. n Make sure the gearbox reservoir incorporates a visible sight gauge that is clearly marked with the upper and lower reservoir limit lines—much like a dipstick. n Consider the use of synthetic lubricants for your gearboxes. They will run cooler than mineral-based oils. (The use of synthetic lubricants in gearboxes has been shown to reduce energy consumption by as much as 4%.) LMT Ken Bannister is lead partner/principal consultant with EngTech Industries, Inc. (www.engtechindustries.com). Besides serving as a contributing editor with LMT and Maintenance Technology (where he’s also known as “Dr. Lube”), Bannister is the author of the best-selling book Lubrication for Industry and the Lubrication Section of the 28th edition Machinery’s Handbook. Telephone: (519) 469-9173; e-mail: kbannister@engtechindustries.com. EDITOR’S NOTE: Ray Thibault is on vacation. He’ll return with a feature article in LMT’s November/December issue. SEPTEMBER/OCTOBER 2010

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PROCESS IMPROVEMENTS This is a follow-up to an NSK-supplied article on three other reasons for bearing failure— creep, flaking and smearing—that ran in the September/October 2009 issue of LMT.

More

3 Reasons For Premature Bearing Failure (And How To Avoid Them) Listening to what your failed bearings are telling you today can help minimize problems tomorrow.

Y

ou’ve heard it before: Every failed bearing tells a story— one that can help you identify machinery problems, maintenance issues, bearing-selection errors, installation problems and more. Are you listening?

Premature bearing failure is costly, both in terms of component replacement and unscheduled downtime. Fortunately, many types of bearing damage can be spotted, assessed and addressed—before failure occurs. The ability to proactively identify issues that affect bearing performance and wear is key to ensuring that your facility stays up and running as required.

Special To LMT From NSK

Fig. 1. What seizure looks like

14 | LUBRICATION MANAGEMENT & TECHNOLOGY

SEPTEMBER/OCTOBER 2010

PROCESS IMPROVEMENTS

Understanding types of bearing damage, along with their causes and solutions, can help boost reliability and cut maintenance. A previous article (“3 Reasons for Premature Bearing Failure,” pgs. 14-16, LMT, September/October 2009) discussed creep, flaking and smearing. In this follow-up, the focus is on three more killers: seizure, cage damage and fretting. #1. Seizure When sudden overheating occurs during rotation, bearings can become discolored. The raceway rings, rolling elements and cage begin to soften, melting and becoming deformed as damage accumulates. WHAT TO LOOK FOR: Discolored bearing elements and melting of the roller surface, resulting in adhesion of worn particles from the cage

■ Large moment load

Possible causes…

■ Shock or large vibration

■ Poor lubrication

■ Excessive rotation speed, sudden acceleration and deceleration

■ Excessive load

■ Poor lubrication

■ Excessive rotational speed

■ Rise in temperature

■ Excessively small internal clearance

Solutions…

■ Entry of water and debris

■ Review mounting method.

■ Poor precision of shaft and housing, excessive shaft bending

■ Reduce vibration.

Solutions…

■ Re-select cage type, lubrication method and lubricant.

■ Review lubricant and lubrication method.

■ Assess temperature, rotation and load conditions.

■ Investigate suitability of bearing type.

#3. Fretting Fretting is the specific type of wear that occurs as a result of repeated sliding between two surfaces. It occurs at the fitting surface and the contact area between the raceway ring and rolling elements. WHAT TO LOOK FOR: Reddish-brown or black worn particles

■ Study the preload, bearing clearance and fitting. ■ Improve the sealing mechanism and mounting method. ■ Check precision of the shaft and housing.

Fig. 2. What cage damage looks like

#2. Cage damage Several types of cage damage can affect the life of a bearing. These include fracture of the cage pillar, deformation of the side face and wear of pocket or guide surfaces. WHAT TO LOOK FOR: Fractured cage Possible causes… ■ Poor mounting or bearing misalignment ■ Poor handling

SEPTEMBER/OCTOBER 2010

Fig. 3. What fretting looks like www.LMTinfo.com | 15

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APRIL 26-29, 2011 We thank all attendees, presenters and exhibitors for helping us make MARTS 2010 a rousing success. MARTS 2011 promises to be even bigger and better! Check regularly on www.MARTSconference.com for event news and scheduling updates.

Reliability Keeps Giving Voice To Autism As in 2010, MARTS 2011 will kick off with another “Reliability Gives Voice to Autism” (RGVA) charity event. This gala evening of fun, food and entertainment at MARTS 2010 was this year’s #1 industrial contributor to the Autism Society - Illinois. Stay tuned for details on how you and your company can be part of this great cause. “I am forever grateful for the efforts made by the organizers and volunteers of RGVA on behalf of the Autism Society - Illinois. With the success of the inaugural event, I am looking forward to the 2011 Reliability Gives Voice to Autism with exuberant anticipation.” … Michael Gallivan, President, Board of Directors, Autism Society - Illinois

We’re grateful, too…Applied Technology Publications is delighted that others across the reliability community have chosen to join us in the battle to raise awareness and funding for autism. To all of you, thank you for your contributions and good luck in your fight. For more information, contact Bill Kiesel at bkiesel@atpnetwork.com

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Possible causes (of fretting)… ■ Poor lubrication ■ Vibration with a small amplitude ■ Insufficient interference Solutions… ■ Use appropriate lubrication for bearing type and application. ■ Apply a preload. ■ Check the interference fit. ■ Apply a film of lubricant to the fitting surface. Remember this When a bearing is damaged, it doesn’t affect just a single piece of equipment: It can cause entire operations to grind to a halt. No facility or machinery is immune to unexpected bearing failure. When this type of failure occurs, the right response is crucial. While your immediate concern may be to install a replacement component, a proper assessment of the bearing damage should follow in order to pinpoint its actual cause. Failure to find the root cause of the problem increases the risk of unnecessary repeated failures, downtime and expense. Proactive bearing-failure analysis prolongs bearing life, improves productivity and reduces maintenance costs. Take the time to identify and resolve issues around bearing selection, mounting, lubrication and application. When additional technical expertise is needed, ask an industrial specialist from the manufacturer to perform a failure analysis and recommend the most appropriate solution. LMT To learn about the many NSK products designed to withstand demanding operating conditions, as well as a wealth of resources, tools and services to help you achieve maximum uptime, please visit www.thinknsk.com. For more info, enter 02 at www.LMTfreeinfo.com

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Today’s Entitlement / Tomorrow’s Privilege

T

he North American electricity system is one of the great engineering achievements of the past 100 years. This infrastructure represents more than $1 trillion in asset value, more than 200,000 miles of transmission lines operating at 230,000 volts and greater, 950,000 megawatts of generating capability and nearly 3500 utility organizations, serving more than 100 million customers (or well over 300 million people). Providing reliable electricity is an enormously complex technical challenge, even on the most routine of days. Unfortunately, this incredible feat of engineering is destined to failure. It’s a sad testament to a country that still leads the world in manufacturing and quality of life. Few of us have control over our electric service. Most of us don’t give it a second thought— except when our monthly bill comes or lights go out. The average American considers electricity an entitlement, rather than a privilege. That’s not the way it is in much of the world. Imagine living in Iraq or India, where countless people rely on generators for their power requirements and are lucky to have electricity only four to eight hours per day. Whoa! That could never happen “here,” you say. Don’t count on it. The issues There are a number of issues facing the power industry that will impact each and every American (and whether we’ll have enough electricity in the future). The most significant of these, in my opinion, involves the clean-air legislation Washington is debating. Ask any investor-owned power-company executive about cap and trade, clean coal and carbon sequestration, and you’ll hear general concern about rising costs and profit margins. A utility must be able to pay investors some return or it won’t have any investors. If it isn’t making money or is constantly operating on the edge, no one will want to lend it any money. What does all this have to do with keeping your lights on? If the Clean Air Act passes as it’s currently written, a number of older (coal) plants won’t be able to meet

18 | UTILITIES MANAGER

the new standard. In fact, several large utilities are already planning to shut down older coal plants in anticipation of the new legislation—due to the cost of bringing them into compliance. What then? Don’t bet on wind or solar to match the power generated by the base-loaded facilities we shut down.

Energy conservation will only cover a portion of the gap between our electricity supply and demand. Utility companies must look out for their investors. They can’t run the risk of building new coal plants only to find out they don’t meet the “new” standards. Nor can they invest in nuclear plants without some government loan guarantee to assist in the high cost of construction. And don’t forget, plans for new coal- and nuclear-powered plants can’t go anywhere without the need—and high costs— to deal with various special-interest groups that dot the power-industry landscape. The reality Energy conservation will only cover a portion of the gap between our electricity supply and demand. The remaining portion must come from base-loaded power plants. Proactive utilities are building gas-fired combined-cycle plants to meet customer demands. It’s a calculated risk, given the spike in natural gas prices in the late ’90s. When all is said and done, however, it is the path of least resistance. UM Reference: U.S.-Canada Power System Outage Task Force—Causes of the August 14th Blackout Bill Livoti is a fluid power and power industry engineer with Baldor Electric Company. Telephone: (864) 281-2118; e-mail: wclivoti@baldor.com.

VOLUME 5 / NO. 4

UTILITIES MANAGER UM

Protecting & Optimizing Your Air Compressors Count on synthetic lubricants to help you do it all!

Jane Alexander, Editor with Michael J. Hawkins ExxonMobil Lubricants & Specialties

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ir compressors are everywhere. They’re one of the most valuable and widely used power sources for industrial and commercial businesses in the world. Over the past decade, the marketplace for these workhorses has gone through a dramatic transformation. The need to improve productivity and lower costs has led to significant changes in compressorcomponent technology and designs, with leading manufacturers introducing increasingly advanced units that are more compact— and more powerful—than ever. If your processes require air compressors, protecting and optimizing their performance should be at the top of your to-do list. Consider the following tips. They can help you ensure that your compressors deliver the reliability and performance your operations demand. Protection and optimization start with the correct lubricant In most industrial facilities and many off-highway applications, today’s air compressors operate under extreme pressures and generate extremely high amounts of heat through adiabatic compression. (This is similar to the process used to ignite the fuel-air mixture in a diesel engine.) In these types of operating conditions, high-performance, fully synthetic lubricants offer a number of advantages over mineral-based products. For example, Mobil Rarus SHC 1020 Series oils are formulated with an advanced base oil and a proprietary additive system that assures exceptional resistance to oxidation, enabling them to deliver long-lasting protection and reliability. By comparison, conventional mineral oils often break down when subjected to hightemperature conditions, leading to harmful deposits that can damage critical compressor components.

SEPTEMBER/OCTOBER 2010

www.LMTinfo.com | 19

UM UTILITIES MANAGER

ROI From Oil Analysis Use of synthetics results in a number of benefits, including… ■ Cleaner compressors, which leads to longer running periods between maintenance intervals ■ Enhanced oxidation and thermal stability, which minimizes sludge and deposit formation, even under extremely high and low temperatures, and extreme load conditions ■ Higher load-carrying ability, which minimizes wear of bearings and gears ■ Increased water separability, which reduces sludge formation in crankcases and discharge lines, as well as blockages of coalescers and inter- and after-coolers ■ Improved rust and corrosion resistance, which protects internal components More protection and optimization “must-dos” Check for air leaks. You’ve heard it before: Running a compressor with air leaks is like driving a car with the emergency brake engaged. It wastes energy, reduces output capacity, shortens equipment life and increases maintenance costs. For example, the air leaking from a typical 1/8” hole consumes about one horsepower of energy. Keep operating pressures at the minimal requirement. This is best accomplished by identifying the maximum application-pressure requirement of the system. To this, add the conveyance pressure loss, as typically about 5 psi are required to move air from the compressor to this application. The sum of these two pressures should be the pressure setting of the receiver tank. For example, if the maximum system application pressure requirement is 75 psi, then the receiver tank should be maintained at 80 psi. Only minor adjustments should be necessary to fine-tune this set-point.

For most companies, quarterly oil analysis is recommended for both reciprocating and rotary screw compressors. Such testing should be used to identify the condition of the in-service lubricant, as well as the presence of any wear metals indicative of a potential developing failure. The presence of any harmful contaminants, such as dirt, water and/or coolant, should also be identified. According to ExxonMobil, its Signum Oil Analysis Program is an advanced, online oil-analysis service that lets users register equipment, specify tests, print out labels required to send samples to ExxonMobil laboratories for analysis, and then download results, all from the convenience of their computers. …JA

Similar to air leaks, running at excessively high pressures results in shortened compressor and component life, along with increased maintenance and repair costs. Increased pressures also result in increased heat, which can significantly shorten the life of compressor lubricants, requiring frequent oil changes. (For every 2-psi reduction in operating pressure, there’s about a 1% increase in efficiency.) To get the most out of your compressor, make sure that intake air filters are routinely replaced and that all induction air piping and manifolds are tight and leak-free. Periodic white-glove inspections of all induction-piping surfaces should be performed to validate that internal surfaces are maintained dust-free. The source of any dirt or deposits found should be immediately traced back to the point of origin and repaired. LMT A 17-year veteran of ExxonMobil, Mike Hawkins is the global brand manager for the company’s flagship Mobil SHC brand of high-performance synthetic lubricants. For more info, enter 251 at www.LMTfreeinfo.com

Understanding Lube Compatibility Many compressor manufacturers offer their own line of lubricants. These are often supplied under private-label agreements with lubricant manufacturers and blenders. These products are engineered to promote optimal equipment performance, as well as to be compatible with the materials used for internal components like seals and hoses. Before changing lubricants, it is important to consider the new product’s compatibility, not only with the materials of the compressor’s components, but with the previous lubricant used in the unit. The new lubricant’s formulation and

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LUBRICATION MANAGEMENT & TECHNOLOGY

performance can be compromised if it is not compatible, potentially resulting in increased component wear, accelerated instances of oxidation, degradation of additives and elevated particle count. Since lubricants are engineered with complex chemistries, maintenance professionals are advised to seek the technical advice of an expert lubricant supplier with an in-depth knowledge of compressors. This type of expert will be able to provide data about compatibility testing and instructions for the proper flushing procedures to help promote a smooth conversion.

SEPTEMBER/OCTOBER 2010

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For more info, enter 68 at www.LMTfreeinfo.com ©2008 Baldor Electric Company

THE GREEN EDGE Moving automobile manufacturing along. . .

When an auto-parts maker needed heightened performance, a switch to this synthetic was an important part of the solution.

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ith downtime at an unacceptable level in an auto-parts maker’s die-casting operation, a solution was needed to not only boost equipment uptime, but also meet higher performance and productivity demands. After an assessment of operating conditions, product chemistry, equipment inefficiencies and performance expectations, specialists from Quaker Chemical Corp. suggested a conversion from water glycol (HFC) fire-resistant hydraulic fluid to a higher-performance product, specifically its biodegradable QUINTOLUBRIC 888 series fireresistant hydraulic fluid (HFD). HFD hydraulic fluids are fire-resistant and do not contain water. They’re usually based on synthetic base stocks

or esters that combine reasonable to good fire-resistant properties with excellent lubrication performance. According to the manufacturer, QUINTOLUBRIC HFD is engineered to maximize performance of equipment that’s designed to operate with customary mineral-oil technology. When conversion at the die-cast operation was complete, operating results showed significant improvement: Pump wear was reduced by 91%, and seal life increased by 250%. The die-caster also noticed that pump and motor noise were reduced and that fluid adjustments were no longer necessary, saving additional time and resources. Based on previous measurements, this end-user could now expect its pumps to run up to 10 years on the QUINTOLUBRIC fluids, compared

with a maximum of two years on water glycol fluids. Quaker notes that the additional material cost of HFDs is outweighed by their benefits, especially where high performance is needed. Furthermore, the QUINTOLUBRIC 888 series products are not only biodegradable, they provide low aquatic toxicity, which makes them appropriate for environmentally sensitive applications. These fluids are approved by FM Approvals, a member of the FM Global group, as a less-hazardous hydraulic fluid. They are also typically compatible with other HFD-U type fluids with similar chemistries, as well as with mineral oils. LMT Quaker Chemical Corp. Conshohocken, PA For more info, enter 30 at www.LMTfreeinfo.com

DOES YOUR COMPANY HAVE A GREEN EDGE? E-mail your product and service news to: gpietras@atpnetwork.com For information on advertising in the Green Edge section, contact KATHY JAROS at: Phone: (847) 382-8100 ext. 117 / Fax: (847) 304-8603 / E-mail: kjaros@atpnetwork.com

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LUBRICATION MANAGEMENT & TECHNOLOGY

SEPTEMBER/OCTOBER 2010

© ICETRAY - FOTOLIA.COM

Biodegradable Hydraulic Fluid Boosts Die-Caster’s Productivity And More

THE GREEN EDGE

Wind-Turbine Lube System

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Worm-Gear Replacements

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he Timken® Wind Energy Lubrication System supplies wind-turbine main shaft bearings with continuous lubrication via a single pump working with either a seriesprogressive or injector-based form delivery. The HP (seriesprogressive) system, uses a conventional method for the pressure-purging of old grease. The LP (injector-based) system has an active-purge system to remove old grease without internal bearing-cavity pressure. Both systems deliver up to NLGI No. 2 grease. Both feature an 8-liter standard grease reservoir for 1X yearly maintenance, with stirring paddle and wiper to minimize air pockets and grease separation.

rove Gear says that its IronMan E Series gear reducer, which runs at 90% efficiency to maximize system effectiveness, offers rapid ROI through reduced operating cost and motor downsizing opportunities. With mounting base kits, this compact product can be dropped in as a direct replacement for multiple sizes of worm-gear speed reducers. (The manufacturer notes that because of its modular versatility, the E Series fits 90% of the U.S. worm gear market.) Shaft kits ranging from 1” to 1-1/2” are designed to plug into a standard hollow output shaft. Four models are available, with double reduction ratios from 7.8:1 to 60:1 and power to 8.50 hp. Triple reduction units are available by adding a ratio multiplier. The E Series is packed with a number of premium features, including synthetic lubricant, covers sealed with o-rings and Viton® double-lip seals.

The Timken Co. Canton, OH

Grove Gear Union Grove, WI

For more info, enter 31 at www.LMTfreeinfo.com

For more info, enter 33 at www.LMTfreeinfo.com

Green Insight At FABTECH 2010

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echni-Glide from Hydrotex® is an environmentally “intelligent” fluid designed for use in all types of cable-pulling operations, particularly where there’s a concern over ground water, soil or water contamination. This fluid is non-toxic, non-bioaccumulative, chemically inert and has low VOC. It enables smooth cable pulling under high sidewall bearing pressures and leaves no sticky residue after drying. According to the company, the product is compatible with all commonly used cable-jacket and conduit materials, and the application rate is up to 60% less than other pulling lubricants.

oes “going green” have to be drain on your bottom line? Quite the contrary. In a “Make Green by Going Green” discussion November 3, at FABTECH 2010 (www. fabtechexpo.com), in Atlanta, GA, experts will focus on ways manufacturers can gain a competitive advantage through sustainable practices. Led by Kristin Pierre, green supplier network manager for the U.S. Environmental Protection Agency, with panelists from a variety of manufacturers, the presentation will provide insight on how implementing a practical lean and green approach to consuming water, gas, utilities and raw materials can benefit both a company and the environment. FABTECH 2010 will be held at the Georgia World Congress Center. It’s a fitting venue for what organizers note is the largest trade show in North America dedicated to a full spectrum of metal forming, fabricating, stamping, tube and pipe, finishing and welding equipment and technology. Admission is free with advance registration before October 30.

Hydrotex Farmers Branch, TX

Fabricators & Manufacturers Association (FMA) Rockford, IL

Non-Toxic Cable-Pulling Fluid

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For more info, enter 32 at www.LMTfreeinfo.com SEPTEMBER/OCTOBER 2010

For more info, enter 34 at www.LMTfreeinfo.com www.LMTinfo.com | 23

SOLUTION SPOTLIGHT

Optimizing Equipment Performance & Reducing Maintenance Costs DuPont’s Krytox has been delivering for more than 50 years.

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any maintenance managers, particularly those with equipment operating under severe conditions such as extremely high or low temperatures and/or harsh chemicals, consider frequent equipment failures to be just another cost of doing business. Those failures, unfortunately, can have a devastating effect on a company’s bottom line. The good news is that many causes of equipment breakdown can easily be corrected—and many of the costs curtailed—with proper lubrication. Switching lubricants made the difference Since their first commercial application more than 50 years ago, DuPont™ Krytox® synthetic lubricants have delivered superior, extended performance in a wide range of applications across diverse industries. Today, with new additives for new challenges, Krytox lubricants are still delivering extreme performance under extreme conditions. Thousands of companies around the world have discovered the many advantages of switching to Krytox lubricants. Here are a few examples: ■ A major U.S. electric utility was able to schedule re-lubrication of the bearing in its hot gas fan-control louver once a year instead of once a month. This not only eliminated disruptive and costly monthly production shutdowns, it reduced the number of times workers would be exposed to hazards associated with this maintenance task. ■ A British titanium-ingot manufacturer was able to significantly extend the service life of the seals in the hydraulic rams it uses to remove large ingots from vacuum furnaces. 24 |

LUBRICATION MANAGEMENT & TECHNOLOGY

Those seals are now replaced every 18 months in planned routine maintenance, instead of every four months. ■ A French airport authority was able to achieve annual savings of US$20,000 - $25,000 on the maintenance of its jet fuel pipeline. Maintenance is now performed every 30 months instead of every four to six months. Unscheduled shutdowns due to valve failures have been eliminated. ■ An American chemical plant was able to improve the performance of its anhydrous ammonia pumps by eliminating shaft wear and doubling the service life of the shaft seals. ■ An Indian manufacturer of textile stenters was able to help its customers extend the re-lubrication interval for the stenter chain bearings from every eight months to once a year. The Krytox value proposition Lubricant selection is key to improving equipment efficiency and uptime—and, ultimately, to saving money on maintenance and lost productivity. It also can help you in your quest to ensure safe operations. While some organizations are reluctant to invest in what they consider to be “more expensive“ types of lubricants, a cost-benefit analysis will quickly show how the right product can contribute to reduced downtime and optimized performance. DuPont Wilmington, DE For more info, enter 35 at www.LMTfreeinfo.com SEPTEMBER/OCTOBER 2010

PROBLEM SOLVERS

Air/Oil Lubrication System

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ijur Delimon’s SPIN-REV Lubricator eliminates residual drift of oil fog or mist during operation. Utilizing a pressurized oil supply and individual metering devices, it can carry a wide range of viscosities to a variety of high-speed, singleand multi-spindle applications. Small quantities of oil are delivered in continuous mode to lube points through flexible lines. A separate oil line is contained coaxially within the air line, preventing condensation from forming. Bijur Delimon Morrisville, NC

Tough Stenter Synthetic

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lüber Lubrication’s Klübersynth CTH 2-260 is formulated for oil-lubricated stenters operating at high temperatures and under increased loads. The company notes that this synthetic doesn’t form lacquer-like residues and evaporates only slightly at high temperatures. The improved viscosity/temperature relation, characterized by a high viscosity index, leads to improved machine cold-starts and reduced power consumption. Klüber Lubrication Londonderry, NH

For more info, enter 36 at www.LMTfreeinfo.com

For more info, enter 38 at www.LMTfreeinfo.com

Pistol-Grip Grease Gun

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perating at 7500 psi, Alemite’s PRIME Pistol Grip Grease Gun includes a dual-leverage feature for operating in volume or pressure mode, an ergonomic, rugged cast handle and a universal follower for cartridge and bulk use. The gun delivers an ounce of grease per 30 strokes and has a cylinder capacity of 16 ounces. A heavy-duty follower spring maintains prime. Alemite Fort Mill, SC For more info, enter 37 at www.LMTfreeinfo.com SEPTEMBER/OCTOBER 2010

For more info, enter 69 at www.LMTfreeinfo.com www.LMTinfo.com | 25

PROBLEM SOLVERS

Extreme-Pressure, Food Grade Synthetic

Laser Level For Oiler Installation

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rico’s Opto Laser Level is designed to make installation of the company’s Opto-Matic Constant Level Oiler quicker and more accurate than in the past. No measuring, leveling or marking is needed. Made of nickel-plated die-cast aluminum to withstand harsh environments, it automatically adjusts oil-levels, verifies existing oil-level set-ups and can be used on previously installed or new oilers.

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RC’s Syntha-Tech™ with PTFE is a non-flammable, zero-VOC blend of synthetics for extreme-pressure applications. NSF H1-registered for use in meat and poultry operations, it stands up in temperatures ranging from -40 to 450 F. According to the company, the product’s PTFE additive minimizes surface contact and friction to reduce wear, extend equipment life and maintain peak operating conditions.

Trico Corp. Pewaukee, WI

CRC Industries Warminster, PA For more info, enter 39 at www.LMTfreeinfo.com

For more info, enter 40 at www.LMTfreeinfo.com

KRYTOX® FLUORINATED LUBRICANTS Krytox® Fluorinated Greases and Oils are: Chemically inert. Insoluble in common solvents. Thermally stable. Wide temperature range (-103º to 800º F). Nonflammable. Nontoxic. Oxygen Compatible – safe for oxygen service. Low Vapor Pressure. Low Outgassing. Useful in Vacuum Systems. Krytox® offers Extreme Pressure, Anticorrosion and Antiwear properties. Contains no silicones or hydrocarbons. Mil-spec, Aerospace and Food Grades available! 203 743-4447 or 800 992-2424 www.miller-stephenson.com

MILLER-STEPHENSON CHEMICAL CO.

Vacuum Cleans Large Coolant Sumps

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XAIR’s 110 Gallon Chip Trapper removes solids such as chips, swarf and shavings from large sumps of used coolants and other liquids. According to the company, coolant that once lasted six weeks can now last six months or more. All solids are trapped in a reusable filter bag, then with a turn of a flow valve, clean liquid is pumped back out. EXAIR Corp. Cincinnati, OH

For more info, enter 70 at www.LMTfreeinfo.com

26 | LUBRICATION MANAGEMENT & TECHNOLOGY

For more info, enter 41 at www.LMTfreeinfo.com SEPTEMBER/OCTOBER 2010

PROBLEM SOLVERS

Tough, Reusable Nuts

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esigned to withstand loosening from vibration, Hard Lock Nuts from Fasteners Plus are intended for critical applications, helping provide a secure connection for safety, as well as reduced maintenance and inspection costs. The nut incorporates a wedge principle to create a self-locking force, preventing screws from coming loose and bolts from breaking. Because there’s no abrasion between the concave and convex elements, the nut is reusable. These products have passed the American Vibration and Impact Test NAS 3350/NAS 3354.

Improved Food Grade Compressor Fluids

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mprovements to Petro-Canada’s PURITY FG Compressor Fluids were made to provide better oxidation stability and anti-wear properties for stronger performance, less downtime and longer equipment life. They can be used in more severe applications, hotter conditions and more difficult environments and/or more oxidatively stressful operations. All fluids comply with FDA 21 CFR178.3570 “Lubricants with incidental food contact,” and are H1-registered by NSF.

Petro-Canada Lubricants, Inc. Mississauga, ON

For more info, enter 44 at www.LMTfreeinfo.com

Fasteners Plus Inverness, IL For more info, enter 42 at www.LMTfreeinfo.com

New Website

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he new Inpro/Seal Website (www.inpro-seal.com) covers each of the company’s technologies, including the Original Bearing Isolator, Air Mizer®, Current Diverter Ring™ (CDR®) and Motor Grounding Seal (MGS®). Users can calculate the ROI of their Inpro/Seal products, submit electronic RFQs, run helpful product animations and more. Inpro/Seal Co. Rock Island, IL

For more info, enter 43 at www.LMTfreeinfo.com SEPTEMBER/OCTOBER 2010

Water-Based Degreaser

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NJ Industries’ GlobalTech® Heavy Duty Degreaser (HDD) is more than 90% water-based, with 100% active ingredients. It’s available in concentrate form, pre-mixed with water or in pre-saturated disposable wipes for quick cleanup of both machinery and parts. This environmentally friendly cleaner has been certified as a Clean Air Solvent by the South Coast (CA) Air Quality Management District. JNJ Industries, Inc. Franklin, MA For more info, enter 45 at www.LMTfreeinfo.com www.LMTinfo.com | 27

PROBLEM SOLVERS

Comprehensive Condition-Monitoring

W Zero-Maintenance Bearings

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ptional zero-maintenance sealed bearings for Schmidt Offset couplings from Zero-Max feature needle bearings with internal micro-poly lubrication, eliminating the need for coupling lubrication. The absence of lube fittings makes for a cleaner coupling setup. The couplings are designed to handle high amounts of parallel offset up to 17” and torque capacities up to 459,000 in-lbs. Zero-Max, Inc. Plymouth, MN

For more info, enter 46 at www.LMTfreeinfo.com

ATCHMAN Intensive Care services by Azima DLI allow plant personnel to quickly initiate online monitoring of machines in need of attention by professional analysts. This service is enabled by the Sprite Roamer™ Intensive Care Unit (ICU), the newest addition to the company’s Sprite online monitoring system family. The Roamer ICU is a portable device that can easily be moved to a machine’s location and be commissioned by plant personnel with minimal training.

Azima DLI Woburn, MA

For more info, enter 48 at www.LMTfreeinfo.com

MQL System For CNC Machines

Self-Priming Gear Pumps

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UNIST, Inc. Grand Rapids, MI

Clark Solutions Hudson, MA

NIST offers the Uni-Max Revolution™, a minimum quantity lubrication system that lets users customize lubricant output for individual tools in their CNC machines. Referred to as MQL technology, it applies small amounts of lubricant to the interface where the cutting tool meets the material being worked. The manufacturer says this reduces friction, removes heat, keeps the part cool and can save up to 90% on fluid-related costs.

For more info, enter 47 at www.LMTfreeinfo.com

28 | LUBRICATION MANAGEMENT & TECHNOLOGY

lark Solutions’ UP Series of compact, self-priming gear pumps come with nickel-plated bronze or PTFE gears, stainless steel or brass pump bodies and stainless drive shafts. Uses include: the transfer of oil, fuel or antifreeze; the pumping of seawater, acids and/or alkaline solutions; and the processing of water. An optional, built-in pressure control on some models can maintain a factory-programmed pressure setting via a microprocessor-based variable speed control circuit that uses an internal pressure sensor for loop feedback.

For more info, enter 49 at www.LMTfreeinfo.com SEPTEMBER/OCTOBER 2010

PROBLEM SOLVERS

Improve Breather Life & Efficiency

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LM notes that its OILMISER™ Reservoir Aspirator for air breathers incorporates two independent, unidirectional passageways in a single cast aluminum body. When the oil level drops, replacement air can enter the reservoir only through the filter above the Inflow Control Gate. When the oil level rises, internal fumes and gases inside the reservoir can exhaust only through the Exhaust Control Outlet port. The absence of back flow helps increase breather service life and efficiency. JLM Systems Ltd. Richmond, BC For more info, enter 50 at www.LMTfreeinfo.com

For more info, enter 71 at www.LMTfreeinfo.com SEPTEMBER/OCTOBER 2010

Lubricate And Loosen

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ano’s Sili Kroil combines the company’s Kroil lubricant with dymethyl silicones. According to the manufacturer, it penetrates to spaces as small as onemillionth of an inch as it dissolves rust and works to loosen frozen metal parts. The non-evaporating product is suitable for use on bearings, hinges, gate valves, slides, chains, locks and more. Kano Laboratories, Inc. Nashville, TN For more info, enter 51 at www.LMTfreeinfo.com

For more info, enter 72 at www.LMTfreeinfo.com www.LMTinfo.com | 29

Index ADVERTISER

SEPTEMBER/OCTOBER 2010 Volume 11, No. 5 •

WEBSITE

CIRCLE #

PAGE #

ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS

A2 Technologies ................................ www.a2technologies.com ....................... 61..................... 2

1300 South Grove Avenue, Suite 105 Barrington, IL 60010 PH 847-382-8100 FX 847-304-8603

ATP Lists ............................................ www.atplists.com .................................... 73................... 30

www.LMTinfo.com

Baldor Electric Company................. www.baldor.com ..................................... 68................... 21

SALES STAFF

Des-Case Corporation ..................... www.descase.com/sample ...................... 62..................... 4 Engtech Industries Inc...................... www.engtechindustries.com .................. 71................... 29 Hy-Pro Filtration .............................. www.hyprofiltration.com....................... 63..................... 7 Inpro/Seal .......................................... www.inpro-seal.com ............................... 75................... 32 Ludeca, Inc......................................... www.ludeca.com ..................................... 65................... 13

KY, OH, TN 135 N. Rocky River Road Berea, OH 44017 440-463-0907; Fax 440-891-1254 JOHN DAVIS jdavis@atpnetwork.com

MARTS .............................................. www.martsconference.com.................... 66................... 16 Miller-Stephenson Chemical Co. .... www.miller-stephenson.com ................. 70................... 26 OILMiser Technology....................... www.oilmiser.com................................... 69................... 25 Royal Purple ...................................... www.royal-purple-industrial.com......... 74................... 31 SME .................................................... www.fabtechexpo.com............................ 64................... 11 SMRP ................................................. www.smrp.org/conference/2010 ........... 67................... 17

AL, CA, CO, DC, DE, FL, GA, MD, MS, NC, NJ, SC, PA, VA, WV 1750 Holmes Drive West Chester, PA 19382 610-793-3093; Fax 610-793-3094 JIM HANLEY jhanley@atpnetwork.com

Strategic Work Systems, Inc. ............ www.swspitcrew.com .............................. 72................... 29

Access LMTfreeinfo.com and enter the circle number of the product in which you are interested, or you can search even deeper and link directly to the advertiser’s website.

AZ, AR, NV, NM, OK, UT 3629 N. Sonoran Heights Mesa, AZ 85207 480-396-9585; Fax 480-264-4789 JERRY PRESTON jpreston@atpnetwork.com

Submissions Policy: Lubrication Management &Technology gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc., permission, by an irrevocable license, to edit, reproduce, distribute, publish, and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned.

CT, ME, MA, NH, NY, RI, VT, ON, QC P.O. Box 1059 Osterville, MA 02655 508-428-3331; Fax 508-428-2545 VINCENT LeGENDRE vlegendre@atpnetwork.com

Customized, Targeted Lists For Your Marketing Needs

ATP

List Services

Ellen Sandkam www.atplists.com 1300 S. Grove Ave., Suite 105, Barrington, IL 60010 847-382-8100 x110 / 800-223-3423 x110 info@atplists.com / esandkam@atplists.com

For more info, enter 73 at www.LMTfreeinfo.com

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LUBRICATION MANAGEMENT & TECHNOLOGY

IL, IN, KS, LA, MI, MN, MO, OR, TX, WA,WI, BC 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 847-382-8100 x108; Fax 847-304-8603 TOM MADDING tmadding@atpnetwork.com IA, MT, NE, ND, SD, WY, AB, MB, SK 1300 South Grove Avenue, Suite 105 Barrington, IL 60010 847-382-8100 x106; Fax 847-304-8603 ARTHUR L. RICE arice@atpnetwork.com CLASSIFIED ADVERTISING 3629 N. Sonoran Heights Mesa, AZ 85207 480-396-9585; Fax 480-264-4789 JERRY PRESTON jpreston@atpnetwork.com

SEPTEMBER/OCTOBER 2010

“...we extended drain intervals from every 15 days to every three months AND reduced engine repairs and replacements.” Luis Garza Kingfisher Marine Most efforts to improve operating efficiency and lower maintenance costs are labor intensive and involve painful cultural changes. Numerous progressive companies have experienced significant cost savings simply by upgrading lubricants. You can learn how by reading the special report ‘Lowest Total Cost of Ownership’. This special report includes extensive case studies that document real-world savings through lubricant upgrades. Get your FREE copy of the ‘Lowest Total Cost of Ownership’ today by calling 866-447-5173 . . .

For more information on Royal Purple, visit royal-purple-industrial.com today.

For more info, enter 74 at www.LMTfreeinfo.com

The Original Bearing isOlaTOr sTrOnger Than ever

As part of Waukesha Bearings and Dover Corporation, Inpro/Seal is stronger than ever…with the horsepower to deliver our high-performing solutions and superior customer service around the globe. Industry-leading bearing protection, unmatched experience and same-day shipments – only with Inpro/Seal. So don’t lay awake at night…trust Inpro/Seal to design and deliver your custom-engineered bearing isolator, right when you need it; our installed base of over 4,000,000 speaks for itself.

Trust Inpro/Seal, the clear leader in bearing isolators.

www.inpro-seal.com For more info, enter 75 at www.LMTfreeinfo.com


LMT Sept/Oct 2010